These days, a car is much more than just a means of getting from A to B. It can also provide intelligent feedback thanks to all kinds of comfort and safety functions. The typical car today has on average up to 100 sensors on board, with the number set to increase further in the future. With the number of sensors on the rise but the available space staying the same, more compact and in some cases also more robust sensors are increasingly required. Innovative production solutions are needed in order for the production process to keep up with this level of sophistication. Belgian company IPTE Factory Automation n.v. has met the new challenge head on with its latest systems. The experts in industrial automation worked with Festo to develop an innovative machine concept for the selective soldering of sensors directly in the housing.


Reliable soldering in the housing
Sensors located outside the car's interior have to withstand harsh environments, with temperatures ranging from below -40°C to over +100°C, and they also need to be corrosion and shock resistant. These sensors are enclosed in a tough housing to protect them. However, the inner parts of the sensor cannot be inserted into the housing fully pre-assembled. Certain soldering work has to be done directly in the housing. Conventional soldering techniques such as wave or reflow soldering are not possible here, since the plastic housing would not be able to withstand the temperatures involved. The only option is the more demanding technique of selective soldering. An essential requirement for this technique is applying the right force at the right angle. The high process quality, repetition accuracy and production speed required for this, call for fully automated processes.